Frequently Asked Questions GRASP
Where can I expect to find alignment problems?
Wherever you have rotating shafts there is a need for alignment. The higher speed the more accurate alignment is required. If an
application is generating vibrations, you should always check the alignment.
Do misaligned machines consume more power?
Misaligned machines generate forces to the bearings and the coupling. This force is converted into heat and can easily be recognized using a
Fixturlaser
thermo sensitive camera.
Do I need to align when I use flexible couplings?
Flexible couplings are necessary. They reduce the detrimental forces, due to misalignment, during the start up until the machines have
reached the operating temperature. A flexible coupling can only absorb a very small amount of misalignment. Even then the components are
exposed to stress and wear quicker. It is therefore important to align the machines for running conditions and not cold conditions.
Benefits of Alignment
I have new machines, do I really need to care about alignment?
A machine, such as motor and pump, is often delivered on a frame or base plate. Plug and play, sort of! Even if the machine is perfectly
aligned from the supplier it does not mean it is perfectly aligned when bolted down and connected to the pipes in your factory. Always check
the alignment before starting the new machine.
Why can’t I refit the overhauled machine in the same position as it was before without doing an alignment check?
Even if you mark up the position before you remove the machine you can not know if it will be positioned correctly.
The alignment requirements for a standard motor/pump installation is 0,08 mm/m or better. It is impossible to
replace a machine within that tolerance without performing an alignment.
Our most effective shaft alignment tools
Fixturlaser XA Pro Art. no 1-0882
Fixturlaser XA Pro is a complete shaft alignment tool
• Wireless: Bluetooth® communication.
• 3-d color animations give express results
• Express mode, the system registers the three measurement points automatically
• CCD technology,
• Large detector surfaces (30 mm)
Fixturlaser UPADXA Art. no 1-0884
Fixturlaser UPADXA is packaged in an angled display box equipped with
a Velcro® fastening that enables attaching it to your arm
• Wireless: Bluetooth® communication.
• 3-d color animations
• Express mode, the system registers the three measurement points automatically
• CCD technology
• Large detector surfaces (30 mm)
Fixturlaser GO Pro Art. no 1-0875
Fixturlaser GO Pro is an uncomplicated laser alignment tool for every maintenance professional
• Wireless: Bluetooth® communication.
• Pre-mounted fixtures
P-0230-GB Benefits of Alignment © Elos Fixturlaser AB, January 2010.
• Compound moves, Horizontal and vertical alignment accomplished without additional shaft rotations.
• CCD technology
• Large detector surfaces (30 mm)
express alignment by fixturlaser
Fixturlaser is one of the world´s leading manufacturers of laser based alignment systems. We develop, manufacture and market laser based measurement
instruments for alignment and positioning of rotating machinery. Our systems are user friendly tools that minimize the number of operations involved in
the alignment process, thus speeding up the process - “Express Alignment by Fixturlaser”.
express service world wide
Fixturlaser has distributors all around the world.
We also have at least one service center on each continent. Our distributors can help you with the upgrades that you need and they can also provide
alignment training sessions for your staff, as well as calibration and repair of alignment systems.
we are certified
Fixturlaser holds certificates for ISO 9001 and ISO 14001. Elos Fixturlaser AB is also a certified supplier of EX-classified alignment systems.
Express Alignment T hrough Real Innovation
ELOS Fixturlaser AB I
P.O. Box 7 I SE - 431 21 Mölndal, SWEDEN I
Tel: +46 31 706 28 00 I Fax: +46 31 706 28 50 I
E-mail: info@[Link] I [Link] I
Benefits of Alignment Benefits of Alignment
Alignment of machines has been performed for over 200 years. Aligning your shafts mean...
• Increased operating time • Increased productivity • Increased production quality
The reasons have not always been obvious, but in the modern world the necessity of alignment
is common knowledge. With today’s optimized machinery, alignment is a vital part in the daily
maintenance work. Machines need to be online continuously with a minimum of interruptions.
A machine breakdown causes devastating loss of production. Nearly 50% of all machine breakdowns
are caused by misalignment.
Shaft alignment can be performed with different tools. The easiest way is to use a ruler or a straight
edge over the two coupling halves and align by eyesight. The result is not very accurate and it is very
operator dependent. A better result can be achieved by the use of mechanical dial indicators. A skilled
and experienced operator can obtain good and reliable measurements, but it takes time and patience.
A far easier and highly accurate way is to use laser based alignment systems. They do not require special
skills and deliver accurate and reliable results.
Misalignment and power consumption
Fr Misalignment has a direct impact on the power consumption. Documented cases have shown
Fr savings ranging from 2 to 17%. The thermogram below shows two different couplings and
Fa the amount of heat generated due to misalignment.
Fa
Misalignment effects on bearings and seals
Definition of misalignment The bearings operating life
C
L10= ( P )3
span is directly affected by
Misalignment is the deviation of relative shaft position from collinear axis of Where the forces it is exposed to. The
rotation when equipment is running at normal operating conditions. P=Fr+Fa=Bearing load
slightest misalignment can
Parallel offset C=Constant depending on bearing type
L10=Lifetime in million turns generate excessive forces to
How is misalignment recognized? the bearings and seals. A mis-
There are several symptoms indicating misalignment. By keeping your eyes open you can find them aligned machine causes stress
without any special equipment. to both bearings and shafts.
• Premature bearing, seal, shaft and coupling failure As an effect of this the seals
• Excessive radial and axial vibrations open up, allowing lubrication
• High casing temperature at or near the bearings or high discharge oil temperature leakage and contamination to enter. All together the bearings lifetime is dramatically shortened.
Angular error • Excessive amount of oil leakage at the bearing seals
• The coupling is hot while it is running and immediately after unit shutdown. Look for rubber
powder inside the coupling shroud
• Loose foundation bolts
Benefits of Alignment – Customer references
• Loose or broken coupling bolts GEORGE A. CAIN, MAINTENANCE ENGINEER, SOLVAY ADVANCED POLYMERS, USA
• Excessive amount of grease on the inside of coupling guard ”We have gone over to laser-based alignment systems for alignment of all rotating shafts in pumps and motors. This is
• Similar pieces of equipment are vibrating less or seem to have longer operating life primarily due to the fact that laser-based systems are easier to use, most noticeably when it comes to documentation and
• The shafts are breaking (or cracking) at or close to the inboard bearings or coupling hubs
storage of measurement data. This makes it easier for me to check that the company’s machines are correctly aligned.
Previously, we had to replace seals every three months, now it’s only every second year, so going over to laser-based align-
Effects of base conditions and thermal variations ment has paid for itself several times over.”
Even if you align your machines properly there is a risk that they break due to misalignment. If the
foundation where the machine is mounted is warped you may have a soft foot condition, i.e. one THOMAS MELBY, OPERATIONS TECHNICIAN, STATOIL TJELDBERGODDEN, NORWAY
of the machine feet has a poor contact with the floor. It is of major importance that this is ”Here at Statoil we have had extremely good use of Fixturlaser’s system for machine alignment. This is reflected in the
corrected before performing the alignment. excellent maintenance economy and availability of our plant – an incredible 99 % this year. We believe that Fixturlaser
If the alignment is performed when the machines are cold, and no compensation for thermal provides one of the best laser-based alignment systems, with good, reliable service which is important for us.”
growth is considered, the machines will probably be running severely misaligned at running tem-
JOUNI WALLIN, SUPERVISOR MAINTENANCE TEAM, NYMÖLLA MILL, STORA ENSO, SWEDEN
perature.
”Before we started to use laser based shaft alignment, we had major problems with the wearing of the coupling’s flexible
elements due to misalignment between the pump and the engine. Nowadays, we rarely have any problems; they are sub-
ject to very few replacements. We also perform laser based alignment of our belt drives, which had to be replaced often
Differences in temperature can cause severe misalignment due to the fact that due to wearing. We now have much less wearing of the belts, and hence less maintenance of these machines, as well as
machine casings and pipes expand with raised or lowered temperature. lower costs.”
Benefits of Alignment Benefits of Alignment
Alignment of machines has been performed for over 200 years. Aligning your shafts mean...
• Increased operating time • Increased productivity • Increased production quality
The reasons have not always been obvious, but in the modern world the necessity of alignment
is common knowledge. With today’s optimized machinery, alignment is a vital part in the daily
maintenance work. Machines need to be online continuously with a minimum of interruptions.
A machine breakdown causes devastating loss of production. Nearly 50% of all machine breakdowns
are caused by misalignment.
Shaft alignment can be performed with different tools. The easiest way is to use a ruler or a straight
edge over the two coupling halves and align by eyesight. The result is not very accurate and it is very
operator dependent. A better result can be achieved by the use of mechanical dial indicators. A skilled
and experienced operator can obtain good and reliable measurements, but it takes time and patience.
A far easier and highly accurate way is to use laser based alignment systems. They do not require special
skills and deliver accurate and reliable results.
Misalignment and power consumption
Fr Misalignment has a direct impact on the power consumption. Documented cases have shown
Fr savings ranging from 2 to 17%. The thermogram below shows two different couplings and
Fa the amount of heat generated due to misalignment.
Fa
Misalignment effects on bearings and seals
Definition of misalignment The bearings operating life
C
L10= ( P )3
span is directly affected by
Misalignment is the deviation of relative shaft position from collinear axis of Where the forces it is exposed to. The
rotation when equipment is running at normal operating conditions. P=Fr+Fa=Bearing load
slightest misalignment can
Parallel offset C=Constant depending on bearing type
L10=Lifetime in million turns generate excessive forces to
How is misalignment recognized? the bearings and seals. A mis-
There are several symptoms indicating misalignment. By keeping your eyes open you can find them aligned machine causes stress
without any special equipment. to both bearings and shafts.
• Premature bearing, seal, shaft and coupling failure As an effect of this the seals
• Excessive radial and axial vibrations open up, allowing lubrication
• High casing temperature at or near the bearings or high discharge oil temperature leakage and contamination to enter. All together the bearings lifetime is dramatically shortened.
Angular error • Excessive amount of oil leakage at the bearing seals
• The coupling is hot while it is running and immediately after unit shutdown. Look for rubber
powder inside the coupling shroud
• Loose foundation bolts
Benefits of Alignment – Customer references
• Loose or broken coupling bolts GEORGE A. CAIN, MAINTENANCE ENGINEER, SOLVAY ADVANCED POLYMERS, USA
• Excessive amount of grease on the inside of coupling guard ”We have gone over to laser-based alignment systems for alignment of all rotating shafts in pumps and motors. This is
• Similar pieces of equipment are vibrating less or seem to have longer operating life primarily due to the fact that laser-based systems are easier to use, most noticeably when it comes to documentation and
• The shafts are breaking (or cracking) at or close to the inboard bearings or coupling hubs
storage of measurement data. This makes it easier for me to check that the company’s machines are correctly aligned.
Previously, we had to replace seals every three months, now it’s only every second year, so going over to laser-based align-
Effects of base conditions and thermal variations ment has paid for itself several times over.”
Even if you align your machines properly there is a risk that they break due to misalignment. If the
foundation where the machine is mounted is warped you may have a soft foot condition, i.e. one THOMAS MELBY, OPERATIONS TECHNICIAN, STATOIL TJELDBERGODDEN, NORWAY
of the machine feet has a poor contact with the floor. It is of major importance that this is ”Here at Statoil we have had extremely good use of Fixturlaser’s system for machine alignment. This is reflected in the
corrected before performing the alignment. excellent maintenance economy and availability of our plant – an incredible 99 % this year. We believe that Fixturlaser
If the alignment is performed when the machines are cold, and no compensation for thermal provides one of the best laser-based alignment systems, with good, reliable service which is important for us.”
growth is considered, the machines will probably be running severely misaligned at running tem-
JOUNI WALLIN, SUPERVISOR MAINTENANCE TEAM, NYMÖLLA MILL, STORA ENSO, SWEDEN
perature.
”Before we started to use laser based shaft alignment, we had major problems with the wearing of the coupling’s flexible
elements due to misalignment between the pump and the engine. Nowadays, we rarely have any problems; they are sub-
ject to very few replacements. We also perform laser based alignment of our belt drives, which had to be replaced often
Differences in temperature can cause severe misalignment due to the fact that due to wearing. We now have much less wearing of the belts, and hence less maintenance of these machines, as well as
machine casings and pipes expand with raised or lowered temperature. lower costs.”
Frequently Asked Questions GRASP
Where can I expect to find alignment problems?
Wherever you have rotating shafts there is a need for alignment. The higher speed the more accurate alignment is required. If an
application is generating vibrations, you should always check the alignment.
Do misaligned machines consume more power?
Misaligned machines generate forces to the bearings and the coupling. This force is converted into heat and can easily be recognized using a
Fixturlaser
thermo sensitive camera.
Do I need to align when I use flexible couplings?
Flexible couplings are necessary. They reduce the detrimental forces, due to misalignment, during the start up until the machines have
reached the operating temperature. A flexible coupling can only absorb a very small amount of misalignment. Even then the components are
exposed to stress and wear quicker. It is therefore important to align the machines for running conditions and not cold conditions.
Benefits of Alignment
I have new machines, do I really need to care about alignment?
A machine, such as motor and pump, is often delivered on a frame or base plate. Plug and play, sort of! Even if the machine is perfectly
aligned from the supplier it does not mean it is perfectly aligned when bolted down and connected to the pipes in your factory. Always check
the alignment before starting the new machine.
Why can’t I refit the overhauled machine in the same position as it was before without doing an alignment check?
Even if you mark up the position before you remove the machine you can not know if it will be positioned correctly.
The alignment requirements for a standard motor/pump installation is 0,08 mm/m or better. It is impossible to
replace a machine within that tolerance without performing an alignment.
Our most effective shaft alignment tools
Fixturlaser XA Pro Art. no 1-0882
Fixturlaser XA Pro is a complete shaft alignment tool
• Wireless: Bluetooth® communication.
• 3-d color animations give express results
• Express mode, the system registers the three measurement points automatically
• CCD technology,
• Large detector surfaces (30 mm)
Fixturlaser UPADXA Art. no 1-0884
Fixturlaser UPADXA is packaged in an angled display box equipped with
a Velcro® fastening that enables attaching it to your arm
• Wireless: Bluetooth® communication.
• 3-d color animations
• Express mode, the system registers the three measurement points automatically
• CCD technology
• Large detector surfaces (30 mm)
Fixturlaser GO Pro Art. no 1-0875
Fixturlaser GO Pro is an uncomplicated laser alignment tool for every maintenance professional
• Wireless: Bluetooth® communication.
• Pre-mounted fixtures
P-0230-GB Benefits of Alignment © Elos Fixturlaser AB, January 2010.
• Compound moves, Horizontal and vertical alignment accomplished without additional shaft rotations.
• CCD technology
• Large detector surfaces (30 mm)
express alignment by fixturlaser
Fixturlaser is one of the world´s leading manufacturers of laser based alignment systems. We develop, manufacture and market laser based measurement
instruments for alignment and positioning of rotating machinery. Our systems are user friendly tools that minimize the number of operations involved in
the alignment process, thus speeding up the process - “Express Alignment by Fixturlaser”.
express service world wide
Fixturlaser has distributors all around the world.
We also have at least one service center on each continent. Our distributors can help you with the upgrades that you need and they can also provide
alignment training sessions for your staff, as well as calibration and repair of alignment systems.
we are certified
Fixturlaser holds certificates for ISO 9001 and ISO 14001. Elos Fixturlaser AB is also a certified supplier of EX-classified alignment systems.
Express Alignment T hrough Real Innovation
ELOS Fixturlaser AB I
P.O. Box 7 I SE - 431 21 Mölndal, SWEDEN I
Tel: +46 31 706 28 00 I Fax: +46 31 706 28 50 I
E-mail: info@[Link] I [Link] I